Integrated footwear construction and related method of manufacture

ABSTRACT

An integrated article of footwear including a waterproofing membrane direct attached to an upper of the footwear. An outsole is further secured to the membrane and/or the upper. In one embodiment, the membrane includes a visible aesthetic bead in the footwear forefoot region, but not the heel region. The membrane may be of greater thickness in the forefoot region to provide added rigidity. A heel cradle is positioned in the footwear heel region between the upper and the outsole. The footwear provides the durability of a direct attach construction in the forefoot and the comfort and cushion of an athletic construction in the heel of the shoe. A method for constructing the footwear includes direct attaching the membrane to an upper of the shoe. Optionally, a heel cradle is disposed in the heel region of the shoe, and the outsole is secured to the heel cradle and/or upper there.

This application claims benefit of U.S. Provisional Application No.60/551,392, filed Mar. 9, 2003, and is a continuation-in-part of U.S.application Ser. No. 10/725,647, filed Dec. 2, 2003, which claimsbenefit of U.S. Provisional Application No. 60/491,491, filed Jul. 31,2003.

BACKGROUND OF THE INVENTION

The present invention relates to footwear and, more particularly, to afootwear construction and method for making the same.

There is an ongoing effort in the footwear industry to produce footwearthat provides durability, a high level of comfort, and a degree ofwaterproofing. Such footwear is targeted toward individuals who standfor long periods of time on hard surfaces (e.g., concrete floors), whomust travel on foot for significant distances or who must occasionallytraverse wet or damp areas or worksites.

Conventional footwear constructions, however, provide one of durability,comfort, or waterproofing, but usually not all three because thefeatures required for these characteristics typically negate oneanother. For example, one construction known for its durability is adirect attach construction, which may be incorporated into work orhiking boots. In such a construction, a midsole, constructed of a soft,resilient material provides a uniform-depth cushion along the entirelength of the shoe between the upper and the more rigid and durableoutsole. This midsole is constructed with a process in which the midsoleis “direct attached” to the upper, from heel to toe, in a mold. In otherwords, the midsole material is injected into a mold adjacent the upperand, as the material cures, it bonds to the exposed portion of the upperalong the entire length of the footwear. To complete the footwear, anoutsole is glued to the midsole opposite the upper. This direct attachmidsole is thus joined very securely to the upper to provide a durableshoe.

Although this construction is durable and aesthetically pleasing, itsometimes compromises the flexibility and comfort of the shoe due to thebond between the midsole and the upper, as well as the uniform depth,sheet-like construction of the midsole along the entire length of thefootwear. Moreover, because the midsole and outsole are substantiallyuniform from heel to toe of the footwear, there is little or no cushionvariation provided for different regions of the foot, which in turn maycompromise the comfort of the shoe. Finally, the midsole, by itself, hasminimal waterproofing capabilities.

Although different constructions exist that provide desired durability,waterproofing characteristics, or comfort, there remains an unmet needfor an integrated footwear construction that provides the best of allrequirements.

SUMMARY OF THE INVENTION

The aforementioned problems are overcome in the present invention, whichprovides a footwear construction including a membrane direct attached toan upper in the forefoot and the heel regions of the footwear to providea waterproof barrier. The membrane includes an aesthetic bead in theforefoot region of the footwear, but not in the heel region.

In another embodiment, the thickness of the membrane is greater in theforefoot region than in the heel region. The membrane bead may bedisposed around a perimeter of the membrane in the forefoot regionadjacent the thicker portion of the membrane.

In another embodiment, the footwear construction may include a heelcradle to provide the desired amount of heel cushioning and stability.The heel cradle may be secured to the membrane and/or upper rearward ofthe thicker portion of the membrane.

In yet another embodiment, a water impermeable liner is secured orjoined with the upper. This liner cooperates with the membrane toprovide an ever greater degree of waterproofing.

The footwear of the present invention is manufactured by: directattaching a membrane to an upper in the forefoot and heel region, themembrane including a thicker portion and/or an aesthetic bead in theforefoot region; joining the upper and/or membrane to an outsole; andoptionally, securing a heel cradle between the upper and the outsole inthe heel region.

The present invention provides a revolutionary footwear constructionwith an unparalleled combination of durability and comfort. The directattached membrane makes the forefoot region of the footwear durable andwell-supported. The membrane also renders the footwear substantiallywaterproof in regions and along seams previously difficult towaterproof. In the heel region of the footwear, the heel cradle providesextraordinary comfort by absorbing and returning energy produced inevery step, and by offering a comfortable platform to stand on for longperiods.

These and other objects, advantages and features of the invention willbe more readily understood and appreciated by reference to the detaileddescription of the invention and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is side elevational view of an article of footwear incorporatingthe integrated construction of the present invention;

FIG. 2 is a sectional view of the footwear taken along line 2-2 of FIG1;

FIG. 3 is an exploded perspective view of the footwear;

FIG. 4 is a sectional view of the footwear taken along line 4-4 of FIG.2;

FIG. 5 is a sectional view of the footwear taken along line 5-5 of FIG.2;

FIG. 6 is perspective view of a membrane of the present invention;

FIG. 7 is a sectional view of the membrane taken along line 7-7 of FIG.6;

FIG. 8 is a sectional view of the membrane taken along line 8-8 of FIG.6;

FIG. 9 is a sectional view of the membrane taken along line 9-9 of FIG.6; and

FIG. 10 is a sectional view of a direct attach method of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

A shoe incorporating the integrated construction of the presentinvention is shown in FIG. 1 and generally designated 10. For purposesof the disclosure, the present invention is described in connection witha ¾ height boot, however, the present invention is well suited for usewith other types of soled footwear.

In general, the shoe 10 includes an upper 20 secured to an outsole 40. Amembrane 60 is direct attached to the upper 20. The direct attachmembrane shown includes a bead 62 that terminates short of the heelregion of the shoe. The heel region includes a heel cradle 50 positionedbetween the upper 20 and the outsole 40. Here, the upper and/or membranemay be secured to the heel cradle and/or outsole with an adhesive orcement.

As used herein, the term “arch region” refers generally to the portionof the shoe corresponding to the arch of the wearer's foot; the term“forefoot region” refers generally to the portion of the shoe forward ofthe arch region corresponding to the forefoot (e.g., the ball and thetoes) of a wearer's foot; and the term “heel region” refers generally tothat portion of the shoe rearward of the arch region corresponding tothe heel of the wearer's foot. The forefoot region 42, arch region 43and heel region 44 are generally identified in FIG. 2, however, it is tobe understood that delineation of these regions may vary depending uponthe configuration of the footwear.

The upper 20 is generally conventional and will not be described indetail. Suffice it to say that the upper 20 includes vamp 22, quarters24 and backstay 26. With reference to FIG. 3, the upper 20 includes alower portion that transitions to an allowance 23, also referred to as aperipheral allowance, which is folded inward toward the center of thefootwear. This peripheral allowance, and in some cases, the lowerportion of the upper, is direct attached to the membrane 60, asdescribed in detail below. The peripheral allowances may be secured tothe insole 70, or optionally strobel stitched to an insole and/or fabricsock liner (not shown). The upper 20 may be manufactured from leather,canvas, nylon, or other suitable materials and may include a liner (notshown) or other conventional accessories.

A water impermeable liner 72 is optionally secured to an interior of theupper 20. This liner, as shown in FIGS. 2 and 4-5, extends downward,toward the inwardly folded peripheral allowance 23. In one embodiment,the liner terminates a pre-selected distance above the fold of the upperthat forms the peripheral allowance. In another embodiment, the linerextends upwardly to the uppermost portion of the shoe 10. The liner maybe constructed of any material, but preferably is constructed from awater impermeable fabric or material. Suitable materials include thematerial sold under the trademark GORE-TEX, which is commerciallyavailable form W.L. Gore & Associates, Inc. of Newark, Del., and thematerial sold under the trademark SYMPATEX, which is commerciallyavailable from SympaTex Technologies GmbH, Wupperstal, Germany. Theliner ay additionally or alternatively be constructed from a continuouslayer of waterproof thermoplastic or adhesive, which coats the interiorof the upper.

In the region defined between opposing edges of the peripheralallowance, a filler 74 may be disposed. This filler may be constructedfrom a conventional cushioning material, such as polyurethane.

The outsole 40 is manufactured from a relatively hard rubber or othersufficiently durable and wear-resistant material. The bottom 46 includesan outer surface 48 that forms the wearing surface of the outsole 40 andis contoured to the desired heel and tread pattern. The outer surface 48may be textured to improve the traction and aesthetic appeal of theshoe. Optionally, the upper surface 47 of the outsole may he textured asdesired. As shown in FIG. 3, the outsole 40 may include a wall 42disposed in the arch region 43. This wall may be substituted with arounded barrier or eliminated altogether. It also may be disposed in theforefoot region 42 and/or the heel region 44 as desired. The wall mayextend partially or completely across the outsole, and optionallyterminate at the flange 49, which extends upwardly in at least the archregion, and optionally in the heel region. The outsole 40 is secured tothe membrane 60 and the heel cradle 50 with cement or adhesives, or asdesired, direct attached to these components.

As depicted in FIGS. 2-4, the membrane 60 is direct attached to theperipheral allowance 23, and where included, the filler 74 along asubstantial portion of the length of the footwear. In such a directattach construction, the material from which the membrane is constructedbonds directly to the peripheral allowance, the filler, and a lowerportion of the upper. The membrane includes a plate 63, which extendsalong the length of the footwear, and a bead 62, which terminatesforward of the heel region 44 without extending into the heel region.However, in some applications, the bead may extend into at least thearch region. The bead may be secured to the upper 20 substantially onlyin the forefoot region 42, and may extend upwardly and around the lowerperiphery of the upper in the forefoot.

For a clean appearance in the finished footwear, the ends of the bead 62and for the bead flange 64 are disposed behind the flange 49 of theoutsole 40. In this configuration, the ends of these components areconcealed from sight. As desired, the bead 62 and bead flange 64 mayextend to the wall or barrier 42 of the outsole. The membrane and itscomponents may be manufactured from polyvinyl chloride, hard durablerubber, or other materials as desired.

With reference to FIGS. 6-9, the membrane 60 will be described in moredetail. The membrane includes a plate 63, having first 64 and second 69sides. As shown, the first side 65 is formed against and/or bonds to theupper 20 and filler 74 when the membrane is direct attached to thesecomponents. The plate 63 is relatively planar on its upper surface, i.e.the first side, and substantially covers the opening defined betweenopposing peripheral allowances 23 to effectively seal with a waterproofbarrier the lower portion of the upper 20. In the forefoot region 42 ofthe footwear, a first flange 66 extends upwardly adjacent the upper 20,and is secured to the upper there by direct attachment. Also in theforefoot region, the membrane includes a bead 62. The bead extendsdownwardly from the insole plate a pre-selected distance. At thelowermost portion of the bead, a second flange 64, also referred to as abead flange, extends outwardly around a perimeter of the footwear in atleast one of the forefoot region and the arch region. As desired, thebead and flanges may exist anywhere forward of the heel region.

The plate 63 in the region of the footwear where the bead 62 exists maybe of equal or greater thickness than the region of the footwear wherethere is no bead. For example, as shown in FIGS. 2 and 8-9, the firstthickness 68 of the membrane 60 in the forefoot region 42 is greaterthan the second thickness 67 of the membrane 60 in the arch 43 and heelregion 44. In an alternative embodiment, the plate 63 is of asubstantially equal thickness throughout the length, and the bead is adownward extension of the first flange 66 to the bead flange 64. Asdesired, the membrane and all of the flanges, the bead, and the platemay be a single, unitary, integral component.

The membrane 60 and waterproof liner 72, which is secured within or tothe upper 20, may cooperate to render the interior of the uppersubstantially waterproof.

As shown in FIGS. 2-3 the insole 70 extends along the entire length ofthe shoe, and may be constructed of any conventional cushioningmaterial. In the heel region 44 and, optionally, the arch region 43, theinsole is secured via conventional means, for example, adhesives,cement, stitching or the like to the interior side of the peripheralallowance 23 of the upper. Optionally, a shank 86 of steel, plastic orother material is secured to the bottom of the insole 70 in the archregion 43 of the shoe. The shank may be secured to other components ofthe shoe as desired, and may overlap with the other regions, forexample, the forefoot region 47 and heel region 44.

With reference to FIGS. 2, 3 and 5, the shoe includes a heel cradle 50that snugly fits in or adjacent the outsole 40. The heel cradle 50 ispreferably cup-shaped to cradle the heel of the wearer and extendupwardly around at least a portion of the wearer's heel. As shown, theheel cradle 50 is positioned substantially only in the heel region 44and terminates at or slightly within the arch region 43. As desired, thecradle may terminate short of the arch region or may extend beyond thearch region into the forefoot region 42. This heel cradle is securedwith adhesives or cement directly to the upper 20. In the embodimentsshown, the cradle is adhered to the peripheral allowance 23 of the upper20 and optionally, a portion in the undersurface of the insole 70. Theheel cradle is preferably made from a low density cushioning material.In one embodiment, the heel cradle 50 is constructed from an ethylvinylacetate (EVA) foam. The rigidity and the flexibility of the EVA foam canbe varied from application to application as desired.

In the fully assembled footwear shown in FIGS. 2, 4 and 5, the outsole40 is secured in the forefoot region to the membrane 60, and to at leastthe heel cradle 50 in the heel region 44. This securement may beprovided by cement, adhesives or other conventional attachment means.When assembled, the rearmost portion of the bead 62, including the beadflange 64 is adjacent the wall 42 of the outsole, however thesecomponents may also abut against the wall as desired. In constructionswhere the outsole does not include a wall, the heel cradle 50 may extendforward to abut or join with the thicker portion of the membrane, or themembrane 60 may extend rearward to, abut against, or join with the heelcradle. The shank 86 and exposed portion of the underside of the insole70 may or may not be secured to the outsole 40 as desired.

Manufacture and Assembly

Manufacture of the shoe 10 will now be described with reference to FIGS.3-6 and 100, The upper 20 is manufactured using generally conventionaltechniques and apparatus. The desired upper material (not shown) is cutto form the upper. Although not shown, the upper may include multipleelements, such as a vamp, quarters and a back stay. If included, thesepieces of the upper are fitted and sewn together. The water impermeableliner 72 is secured within the upper via adhesives or stitching thatdoes not deteriorate the water impermeability of the liner in thedesired areas. This liner is fitted to the upper so that in the finishedfootwear, it extends downward a sufficient distance so that thelater-added membrane terminates above the lowermost portion of theliner.

The insole 70 is fitted on a last 100, and the fitted upper 20 isstretched over the insole and the last. The peripheral allowance 23 issecured with a cement, adhesive or other attachment means to theunderside of the insole 70. The peripheral allowance 23 may betemporarily tacked or stapled to the last to hold the allowance inplace. The filler 74 may further be cut and trimmed to fit within thevoid defined between opposing sides of the peripheral allowance 23. Thisfiller may be cemented or adhered within this void to the underside ofthe insole 70 and the edge of the peripheral allowance 23 as desired.

With the upper 20 secured to the insole 70 as desired and stretched overa last 100, these components are prepared for a direct attach moldingoperation, which is shown in FIG. 10. The last 100 is lowered againstthe membrane mold 120, which includes side molds 112 and a bottom mold114. Only one side mold 112 is shown in FIG. 10, however, it is notedthat a corresponding side mold opposing the depicted side mold isincluded. Each side mold 112 wraps around the sides of the lasted upper20, and mate with one another at the front and rear of the shoe. Theside molds 112 and bottom mold 114 cooperate to define a membrane cavity130 of varying thickness but running along the length of the footwear asshown. This cavity 130 is greater in depth in the forefoot region thanin the heel region. Moreover, the cavity in the forefoot portion furtherdefines corresponding bead 162 and bead flange 164 voids that, whenfilled with material, form the bead and bead flange of the completedmembrane.

It is noted here that the varying depth and deletion of the beadfeatures in the heel region and/or arch region may be accomplished usinga mold insert 140 with the mold 120. As shown, the insert 140 rests inthe membrane cavity 130, and thereby occupies the space that wouldotherwise be filled by material when that material is injected into thecavity. The insert 140 further extends upwardly to cover the bead 162and bead flange 164 voids so that material cannot enter those voids andform corresponding features in the direct attach process. The insert isgenerally the same shape as the heel and/or arch region of the footwear,and of a depth that is a pre-selected amount less than the depth of themembrane cavity. The insert may also include bead and flange features(not shown) so that these features can more securely interfit with thecorresponding features of the side molds.

The side mold 112 includes a cavity side wall 115 which generally formsa side wall of the finished membrane. The bottom mold 120 may include abase wall 122, which generally forms the bottom of the finishedmembrane. The base mold, or the insert 140 when included, may alsoinclude a membrane terminating wall 124. The molds may be modified toform any portion or combination of side walls, bottom walls or otherwalls as desired. Optionally, the thicker region of the membrane cavity130 in some applications may extend rearward, into the arch region ofthe footwear, short of the heel region. In which case, the terminatingwall may be positioned further rearward.

With the components of the mold 120, i.e., the side molds 112 and thebottom mold 114, positioned to form the membrane cavity 130, theappropriate volume of material to form the membrane 60 is injected orpoured through port 150 into the cavity 130. Preferably, the mold 110holds the upper 20 firmly enough to prevent material from exiting themold 110 from the top of the cavity 130. As the material 131 isintroduced into the cavity 133, it substantially fills the cavity 130until the entire membrane 60 is formed.

The midsole material 131 is allowed to sufficiently cure and directattach the membrane 60 to the upper 20, filler 74, and/or insole 70. Theside molds 110 are moved away from the footwear in the direction of thearrows 111. The last 100 is moved upward in the direction indicated withthe vertical arrow 101. Any excess flashing resulting from the directattach process may be trimmed from the membrane. With the flashingtrimmed from the membrane 60, the membrane is readied for securing theoutsole 40 to it. Optionally, a shank 86 may be secured to theundersurface of the filler 74.

The outsole 40 is injection molded or pour molded from a hard, durablerubber using conventional molding apparatus. Its construction may becompleted before any other components of the footwear are assembled asdesired. The tread pattern 48 on the lower surface 46, the upwardlyextending flanges 48, and the wall 42 of the outsole are formed duringthe molding operation as integral parts of the outsole 40. With theoutsole manufactured, the heel cradle 50 is secured to the outsole 40 inthe heel region 44. In those applications where a large heel cradle isused, the cradle may also be secured to the arch region and possiblyextend into the forefoot region 42 as desired. These components may besecured together with cement, adhesive or other attachment means.

In another step, the outsole 40 is secured with cement or adhesives tothe membrane 60 along the entire length of the membrane. Preferably, theterminating end of the beaded region of the membrane aligns with thewall 42 of the outsole 40 so that it is disposed adjacent and/or abutsthe wall. In one embodiment, the outsole is secured to the remainder ofthe footwear so that the flange 48 conceals the terminating end of thebead 62 and bead flange 64 and provides a clean appearance. In the heelregion 44, the heel cradle is adhered or cemented to the peripheralallowance 23 of the upper, and where exposed, the undersurface of theinsole 70. In the arch region, the outsole is secured to the othercomponents of the shoe as desired.

With the outsole 40 secured to the membrane 60 and heel cradle 50/upper20, the shoe 10 may be removed from the last. A number of conventionalfinishing operations may then be performed on the shoe 10. For example,the edges of the membrane 60, the membrane bead 62, and bead flange 64,and the outsole 40 are trimmed and shaped; and the upper 20 is cleaned,polished and treated as appropriate and necessary.

The above descriptions are those of the preferred embodiments of theinvention. Various alterations and changes can be made without departingfrom the spirit and broader aspects of the invention as defined in theappended claims, which are to be interpreted in accordance with theprinciples of patent law including the doctrine of equivalents. Anyreferences to claim elements in the singular, for example, using thearticles “a,” “an,” “the” or “the,” is not to be construed as limitingthe element to the singular.

1. A footwear construction comprising: an upper including an upperforefoot portion, an upper heel portion, an upper lower portion and aperipheral allowance; an outsole including an outsole forefoot portion,an outsole arch portion, and an outsole heel portion; a firstconstruction securing the peripheral allowance to the outsole forefootportion, the first construction terminating short of the outsole heelportion and the upper heel portion at an end; a heel cradle between theperipheral allowance and the outsole heel portion, a portion of the heelcradle exposed and visible to a viewer; and a flange extending upwardlyfrom the outsole, the flange including a forward part and a reward part,an end of the first construction terminating adjacent the flange forwardpart, and the exposed portion of the heel cradle terminating adjacentthe flange rearward part. 2.-19. (canceled)
 20. The footwearconstruction of claim 1 wherein the first construction is stitchedsubstantially only to the upper forefoot portion.
 21. The footwearconstruction of claim 1 wherein the flange conceals the end of the firstconstruction.
 22. The footwear construction of claim 1 wherein theflange extends upwardly in the outsole arch portion, and wherein thefirst construction terminates in the outsole arch portion.
 23. Thefootwear construction of claim 1 wherein the heel cradle is cemented tothe peripheral allowance and cemented to the outsole heel portion.
 24. Afootwear construction including a forefoot portion, an arch portion, anda heel portion comprising: an upper defining an interior and including aperipheral allowance; a first construction secured to the peripheralallowance in at least one of the forefoot portion and the arch portion,the first construction terminating short of the heel portion at aterminating end; and an outsole including a flange extending upwardlyfrom the outsole and located at least partially in the arch portion, theterminating end of the first construction positioned adjacent theflange, whereby the terminating end transitions cleanly to the flange.25. The footwear construction of claim 24 comprising a heel cradlejoined with the outsole in substantially only at least one of the heelportion and the arch portion.
 26. The footwear construction of claim 25wherein the heel cradle is cemented to the peripheral allowance and theoutsole in the heel portion.
 27. A footwear construction including aforefoot portion, an arch portion and a heel portion comprising: anupper including a peripheral allowance; a first construction secured tothe peripheral allowance in at least one of the forefoot portion and thearch portion, the first construction terminating short of the heelportion at a terminating end; a heel cradle joined with the peripheralallowance in said heel portion; and an outsole joined with said firstconstruction in said forefoot portion, said outsole joined with saidheel cradle, said outsole including a flange that visibly separates thefirst construction from the heel cradle in at least the arch portion.28. The footwear construction of claim 27 wherein said outsole definesan upwardly extending flange and wherein the terminating end isconcealed behind said flange so that the end is unviewable.